Treating iron ore



April 14, 1931, L. BRADLEY 1,800,856

TREATING IRON ORE Filed April 7, 1926 #M BMU@ lNvENToR Patented Apr. 14, 1931 UNITED STAAT-ES PATENT; OFFICE LINN BRADLEY, OF MONTCLAI, NEW JERSEY n mamme :non `can Appueation mea April 7, 192e. serial No. 160,458.

e. g. carbon'monoxide, at a temperature suit able-for effecting such reduction but .below the fusing point of the iron, the necessary heat energy being supplied in a manner which has some advantageous features. The invention also relates to the production of gases containing carbon monoxide, and to the destructive distillation of carbonaceous fuels such as bituminous coal, wood, etc. The invention also relates to the production of hydraulic cement and particularly to the simultaneous and interdependent production of cement and reduced iron.

Among the objects of the invention are the utilization of certain types of iron ores which are not ordinarily considered suitable 23 in their natural condition for charging into blast furnaces; the production of iron of good quality; the utilization of materials associated with the ironin the iron ore; the reduction of iron oxide without fusing the iron 25 produced, facilitating separating of the iron from other materials by magnetic means; the reduction step to be carried out by an exothermic reaction between the reducing gas and the iron oxide, so as to facilitate the 33 operations; the regeneration of the. reducing gas by conversion of carbon dioxide into carbon monoxide by reaction between carbon dioxide and carbonat suitable temperature the utilization of reducing agent tov good ad'- vantage; and other objects and advantages which will appear from the following more` detailed description of the invention.

In this invention, suitable iron oxide is preheated to a suitable temperature for the following step or steps, it is then reduced to iron by means of carbon monoxide gas supplied from any suitable source at a su1table temperature to permlt the reduction step being carried out to the desired degree witha out supplying additional heat other than the sensible heats of the materials and the heat energy of the exothermicreactions; the resulting gases which contain some carbon d1- oxide are then regenerated to again obtain' a,

suitable reducing gas which contains the required amount of carbon monoxide and adapted by temperature and composition to serve in reducing some more iron oxide by an exothermic reaction; and the process is repeated and becomes cyclic insofar as the gas first consists essentially of carbon monoxide, then the reduction step is carried out to yield a mixture of carbon monoxide and carbon dioxide and this mixture is regenerated so as to convert some of the carbon dioxide into carbon monoxide by reaction y with heated carbon, to yield again a suitable gas for the reduction step of the cycle. The gas which accumulates in the system due to removing oxygen from iron oxide is removed either as carbon monoxide or as carbon di'- oxide, preferably the former so as to'thus obtain a gas of high calorific value; and such removal is made intermittently or continuously as may be required.

The hot material containing lthe reduced iron is subjected to a cooling step which avoids contact between air and the hot reduced iron, thus preventing substantial amounts of reoxidation, after Which-the somewhat cooled material, (e. g. a temperature below that at which oxygen-of the air would"`readily reoxidize the reduced iron) is subjected to a magnetic treatment to separate the iron from the other materials. When this other material contains sutiicient silica and alumina, its is zulvantageously mixed with the proper amount of.calcareous material to prepare a raw mix suitable for being burned to produce cement. The heat content of such material is retained and made use of in thecementburning step of the process. Such materials as the glauconite or greensands of New Jersey, etc, are thus indicated as being suitable raw materials for such combined operation, e. g. iron and cement from the same material, with the etiicient utilization of heat units in the combined steps and using calcareous material to properly proportionthe raw mix. (A) 4Fe2O3+1`2C= 4Fe2 12CO432,480 cal. (B) 4Fe2O3+36CO= v l 4Fe2 -l- 24C() -l- 12002 -l- 34,080 cal.

These equations illustratev important( dif- -reduction taking place readily.

mic.

available in `sensible heats and heats ot' reaction tomamtain the. materials at suiicient temperature for the reduction to be carriedl 'i'orna rd without having to resort to heat applied externally, e. g. by electric means, etc. Also, the reducing gases d o not require being preheated to a very high temperature so as to utilize their sensible heat for ol'l'setting the endothermic value of other reactions, such as vwhen hydrogen gas or solid carbon is used as the reducing agent. lVhen hydrogen gas is used as the reducing agent, heat energy must be supplied to counteract the endothermic value of the reaction between iron oxide, e. g. `l"e. and hydrogen. Therefore in the present invention, the reducing gas is essentially CO. and preferably free from hydrogen and carbon dioxide, although the latter can be tolerated in small amounts such that the composition of the gas as regardsC() permits the The C() should be at least l part by volume for each volume of CO2 and the higher its content the better the operation inthe reducing step.

The hot gases, which contain an increased `amount of C()2 and a decreased amount of CO, due to the reduction step, are then passed -into contact \v1th highly heated carbon, preferably free from volatiles. andthus 'anse a reaction between CO2 and C to yield somemore CO. By suitably,regulating this regeneration step, the CO2 can be very materially reduced in amount and the C() materially increased. This increases the amount of vas over that originally present. The surplus O may be removed. retaining in the system the required amount ofhot CO for 4the reduction l step.

.suitable container, in which carbon may be charged, e. g. certain types ot' modern water-gas generators, is given a heating-up treatment by high pressure blast of preheated airl` snliicient to store up a large amount of sensible heat in the carbon, checkers, lining, etc. Then the gas connectors are changed so as to introduce some of the gas which is to be regenerated or discarded, preferably that portion of the gas which is to be removed from the cycle. By passing this portion of the gas through the retort, containing the heated carbon, the contained gases are quite well displaced so as to avoid excessive contamination of the reducing gases. Then, after such a purging treatment, the reducing gases with their contained C()2 are regenerated by passing through this hot mass of carbon,and are thus available in their heated and modified condition for reducing some more iron oxide.

These gases ordinarily are passed through the retort u'ntil Lthe mass of carbon has cooled down to where C()2 does not react with the carbon to form CO, and the gases actually used for the reduction of iron oxide are of fairly uniform temperature, i. e. above that required for eli'ecting the reduction when the preheated ore is used.

Several water-gas generators or retorts may be used, and the gases from the cooler ones mixed with that from the hotter ones so .that the mixed gas is fairly uniform and of' a sulicientvtemperature when it comes into contact with the ore. The carbon used in these generators may be of any suitable kind, due consideration being given to the effect of impurities in the resulting gases on the iron or other products of the process. lVood charcoal may be used, at least to some ext-ent. Coke which is obtained from good quality ofbituminous coal may be used.

The heated products of combustion from the heating-up period are advantageously used inpreheating the air which is used in the high-pressure blast into the generator, so as to eeonomize in fuel, to obtain higher temperature within the retort, and care should be taken to have little if any CO in the' gases or products of combustion leaving the retort on the heating-up step. Suitable fans` blowers, heat exchangers, etc. may be used as found necessary or desirable for effecting thetreatments. A non-oxidizing gas may be used for cooling the reduced` iron product before discharging it into' air, and this gas may be used to preheat or assist in preheating the iron ore charged, and reused inthe cooling step, and this exchange of heat continued.

The invention may be further illustrated by the following descriptions, and by the accompanying diagrammatic How sheet showing various steps and operations and pointing' out various uses of diferentmaterials and various products which may be obtained as a result of the invention.

Suitable iron ore is fed vinto a preheater, then is preheated therein to a suitable temperature; from the preheater the hot ore passes into the reducer, wherein it is reduced by,C,O by anexothermic reaction the reduced ore then passes into the cooler and is there cooled# from the cooler the mixture of reduced iron and gangue passes through acrusher to disintegrate the material further if needed; then it is screened; the screenings are subjected to magnetic treatment to separate the reduced iron from the fine particles of gangue'; the iron may be used for a variety of purposes, e. g. in an open-hearth furnace to make steel` etc.; the fine particles of the gangue may be mixed with the coarse particles of gangue separated by the screening step, then suitably crushed, or ground and mixed with the required calcareous and other materials to prepare a suitable raw mix; the raw mix is-passed into a cement kiln and therein burned to give a suitable clinker for cement manufacture.

The reducing ases are prepared from carbon. Coal may e destructively distilled to yield gases and carbon. The gases may be cooled to separate the volatile liquids from the non-condensed gases and the latter may' be used for heating purposes. The heat required for the treatment of the coal may be obtained in any suitable manner. Hot products of combustion, or hot unburned gases may be brought into intimate contact with coal for the purpose. These hot gases may be passed through a porous mass of finev coal so as to facilitate the distillation andto facilitate transferring the heat to the coal particles. @ther fuel, e. g. combustible gases from one or more steps of the process may be used to supply additional heat for the coal distillation step of the operations. I

ln the treatment of the iron orc, the following method of handling the gases is an advantageous one.. The hot gases from the' regenerator (advantageously carrying more C() than CO2) are passed through the preheater countercurrent to the iron ore in such manner that the iron ore (preferably free from water) is suitably preheated by these hot gases and the gases are suitably cooled.

The cooled gases pass from the preheater through a. suitable fan or blower and then into the cooler and therein are heated by the hot reduced iron and gangue and the solids are cooled to a suitable point, e. g. so that they may be discharged into air without undergoing much if any reoxidation thereby. rlhe reducing gases, e. g. containing alarge percentage of CO, should then be hot enough for passing directly into the reducer wherein the CO reduces iron oxide by an exothermic reaction. However, if these gases are not -hot enough they may be removed, passed vthrough a recuperator of the checker work type and their temperature raised to such a point that they may be then passed into the reducer. It is advantageous, however,` to have these gases hot enough when leaving the cooler to go directly into the reducer. rlhe heat contained in the reducer may be sufficient to raise these'gases to the proper Cil temperature, partly owing to the heat contained in the solids and partly due tothe exothermic reactions occurring therein. The

temperature within the reducer may be determined as required and either raised or lowered in any sutable manner as may be required for the steps. v

The gases leaving the reducer contain more CO2 than when they enteredthe reducer, and are hot. They are passed 'through e. g. a recuperator so adapted as to raise their temperature to a sufficient point for passing into the regenerator. The regenerator contains the highly heated carbon and in this occurs an endothermic reaction which draws upon the heat stored up in the gases as they come from the recuperator. The regenerat'or should be so run that the gases'leaving it contain the desired amount and percentage of CO. As much of this regenerated gas as is required is then again passed into the preheater to again heat up some iron ore and be in turn somewhat cooled.

Suitable valve means are provided wherever required, as Well as the necessary me' be suiiicient to prevent this, by keeping a sutcient amount of the material in the pas-V sageway between the ditferent types ofdevices to act as agas seal and yet permit the desired rate of passage from one device to another and .finally into atmosphere. For example, these interconnecting passageways, for the solids, may be a vertical flue which has a hopper-like top and so arranged as to discharge onto a floor or hearth in the next lower device, the moving floor or hearth serving to keep the vertical flue filled or nearly filled with the fine solids to a` depth of a few inches or feet and thus prevent gases passing through this vertical iiue, and the moving door, or hearth serving to gradually draw solids therefrom while keeping the vertical iiue closed in the manner indicated. A

Some'of the CO gas, between the regenerator and the preheater, or some of the C() and C02 gas, between the reducer and the recuperator, may be withdrawn as required owing to upbuilding of gas volume. The C() gas may be used as such. The CO and CO2 gas may be used as such, or it may even be treated to remove CO2 therefrom, e. g. by reacting with an oxide such as Ca() at a temperature below the dissociating temperatu're of its carbonate. The CO gas may be used in internal combustion engines, or for producing hydrogen from steam, with subsequent removal of the CO2 formed by this exothermic reaction below about 80() deg. C. Thel hydrogen may be purified as needed and used to produce NH3.

The recuperator may be a checkerwork de vice in which fuel, e. g. the CO from the process. or other suitable material is burned, advantageously using preheated air, and thus store up a large amount of heat in the refractories. In this recuperator, it is advantageous to have a large ainountof checkerwork,

and asismall an amount of free space as feasible, and that the checkers be made of high grade refractories which absorb a large amount of heat readily and give it off readily, and stand a very high temperature, thus facilitating the storage of a large amount of `heat in one burning, and by using preheated air and thus getting high iame temperatures, a. large percentage of the total heat generated ean be retained in the recuperator, al-.

ing-up step, the large amount of carbon isv heated to a. high temperature. The gases contain little CO, most of the carbon being burned to CO2 and if removed rapidly enough there is but little if any reversion to CO. The hot products of combustion may then be passed through checkerwork and store up some heat therein in addition to that stored in the carbon and refractories of the regenerator proper. As stated, the products of combustion should -be purged before making use of the regenerator for the production of the gases which are to be used in the reduction of the iron orc.` A portion of these G01-CO2 gases may be used for the purging, and then removed from the cycle in a manner indicated above.

The regeneratedv gases from a plurality of regenerators, operating at different temperatures, are mixed before they are passed into the preheaters, or into the reducers. Some of the gases first coming from a very hot regenerator may be mixed with solne cooler unregenerated gases and this mixture passed through a regenerat'or, thus making use of lsome of theheat stored up in 4the highly before passing to the preheaters or to the reducers. Some of the gases coming directly from the reducers, even if at fairly low teinperature, may be passed through a very hot temperatures at any point in the system, and

the operations are made' more uniform, which is an advantage.

The process provides a novel cycle and a novel means of utilizing as well as supplying or transferring the heat energy necessary in the operation of the steps of the process,

so that a. small amount of reducing agent is required. Excessive gas temperatures are made unnecessary by the steps of the invention and the exot-hermic and the endothermic reactions are carried out in an advantageous manner. Heat energy is utilized to goed advantage; various products are made available; and the substantially full utilization of the solids as Well as the gases is made possible by this process; various so-called low-grade iron ores are thus rendered avallable thereby. lVhere substantially pure oxygen gas 1s available, it may be mixed with CO2 gas in proper ratio and this mixture used for converting carbon into CO. The endotherniic reaction of CO2 on C can be utilized in holding down the temperatures to a suitable point, and the net heat generated can lbe utilized in converting CO2 into CO. The temperature can be controlled by added CO2 gas. l

The gas removed from the cycle, which-is high in CO, may be used in preheating the ore, at-least in part, and it may be used to assist in heating up the carbon in the retort, or in a recuperative stove provided with checker-Work, or it may be used to produce steam and thus power for the operations, or it may be cooled down and used, after scrubbilig if needed, in internal colnbustionengines and thus obtain power required to drive the fans, blowers, and other suitable equipment required to operate the various steps of the process. Where the separated iron is placed i open liearth o other siitable furnaces and melted` the use 'of this CO gas may be resorted to, for which .it is particularly advantageous owing to its high ealorific y value. lVhere the separated material is made into cement, some of thi-s CO-contamlng gasA may be used in the burning step in which cement is made. The amount of such gas yrequired is somewhat less when vthe material is separated from the iron while fairly-hot and retains some of its sensible heat when charged into the cement burning kiln.

In obtaining coke from bituminous coal,

or in the destructive distillation of Wood, or

a mixture of Wood and coal, some of the hot gases from this process, e. g. those which are to be discarded, containing CO, may be used to heat the material and thus effect the decomposition. The sensible heat contained in the discarded gases is thus utilized in producing one of the raw materials of the process in an advantageous manner. The hot gases from the destructive distillation treatment, which may even include some gases resulting from socalled low-temperature carbonization, may be cooled to condense volatile liquids and thus recover these values, while the cooled non-condensed gases are utilized in other Ways, such, for example, as those outlined above. lVater, hydrocarboiis, etc. should be removed with substantial completness before the carbon is used in the Watergas generator. This retort, sometimes called water-gas generator, is not employed for the production ot Water gas in this process, but the gas passed through the retort is of a `-pecial kind, and hydrogen is kept low in amount or is excluded altogether.

An alternative method for furliishing the heat energy needed to permit the reaction (l02+C=2CO-38,880 calories to be carried out in order to regenerate the reducing gases, is to burn fuel in a regenerative stove of rather large size Which contains a. large number of checker brick, thus` heating up the bricks, etc., to a high temperature, e. g. 1500 to 1800 deg. C., utilizing the products of combustion, principally CO2 and nitrogen, Jfor preheating the air which is used in such heating-up step, thus saving heat units, getting a higher temperature in the stove and storing a large percentage of the heat gene erated in the stove to be later picked up by the mixture of CO and C02. The products ot combustion may leave the stove at around 900 deg. C. or considerably lower temperature. When the hot gases, CO and CO5,

come from the reduction step at around 900v to 1,000 deg. C., they may be somewhat cooled beforethey reach the fan or other apparatus by which the gases are caused to circulate through the regenerator and through the apparatus containing the iron ore which is to be reduced, and through the recuperative stove in case one is employed. Such cooling prior to reaching the fan facilitates the operations, e. g. by permitting lower temperatures at the fan. This reduction in heat can be made up by the heat which is stored in the recuperative stoves, so that the mixture of CO2 and CO gases are brought up to a high temperature, e. g. around 1300 to 1600 deg. C and then passed into contact with heated carbon to effect the converson of CO2 to CO, the sensible heatin the gases being sufficient to compensate for the heat energy absorbed in the endothermic reaction involved. When thegases are preheated` in this manner, the fan isv advantageously placed in the cooler position, and if required, a. portion of the gases may be Withdrawn and passed through a fan or bloiver and reintroduced into the flue in such manner and under such velocity that the main body of gases is caused to circulate through the tlues and apparatus. The smaller portion of gases Withdrawn may be somewhat y cooledbefore passing through the fan, thus cooling only a portion of the hot gases and yet being able to circulate the entire volume of gases.

ll'here the heat units required for the endothermic reaction ot CO2 and C to 2C() are obtained from the sensible heat of the mixed gases, it is not essential to use a Water-gas retort or generator for preheating carbon, since the carbon may be kept at a suitable temperature by the sensible heat of the highly heated mixed'gases, and thus gases can be passed through the retort continuously. This avoids the purging treatment to eliminate the. hydrogen, nitrogen, Water vapor, etc., and is otherwise advantageous, although it requires extra apparatus. The heat units whirh are picked up in the recuperator by the mixed CO2 and CO gases, can be previously stored therein by a burning treatment in which producer gas, by-product coke gas, carbon monoxide gas, Water gas, oil, etc., are burned With preheated air in such manner as to store up a large percentage of the heat generated during the combustion of the fuel to CO2, etc.

Anotheralternative lnethod of providing the heat units for the endothermic reaction involved in the conversion of CO2 into CO by contact with hot carbon, is to mix with the carbon, e. g. fairly finely divided, an inert material, for example, calcium oxide, which does not readily fuse under the conditions existing when highly heated,1 then to subject the mixture of carbon and the large amount of inert material to a heating step to store up a considerable number of heat units by burning fuel in such a manner that the material is highly heated With products of combustion or heatdeveloped during the burning of the fuel principally to CO2 (e. g. when coal is used'), then lpassing this highly heated mixture of carbon and inert material, substantially free from contained gases, into another chamber of the apparatus and therein subject it to the action of the mixture of carbon monoxide and carbon dioxide to form more CO. When the inert material `has thus been somewhat cooled, it may be removed from the regeneration chamber into another heating chamber and there have more heat units stored up in it and then again passed into the regeneration chamber, and so on. In this manner, the inert material isl utilized for storing up a large amount of heat which is then carried into the regeneration 'chamber wherein such heat is utilized to offset the heat absorbed in the endothermic reaction; and then the inert material and remaining contained carbon is again heated to store up heat units and later used in another regeneration step. By superimposing these chambers, one above -the other, and provid-ing means for transferring the inert material and carbon from one chamber to the other without carrying much gas from one chamber to the other, and by spreading out the inert material and carbon to present large surface exposed to the gases and obtaining good contact, and by utilizing the ases in the respective stages for use m anot er chamber of a similar type, a considerable degree of heat utilization is effected, care being taken to keep suticient oxygen present in the heating chambers in any suitable mannerl to get a good heat generation' b burning carbon principally to CO2, even if7 oxygen (e. g. in the form of air) has to be introduced in various portions thereof.

The heating of the lcarbon and inert material, as well as the regeneration step (i. e. CO2

-and C into 2CD) may be carried out in their respective chambers, and these respective chambers may be connected in parallel or in series or in seriesparallel, in order to malte effective utilization of the heat units. The air used in the burning or heating step should be preheated by the products of combustion in order to economize in fuel. The fuel may be gaseous, and advantageously some of the CO which is produced in the process.

When the inert material has been treated so that most of its carbon has been converted into CO by reaction with CO2, it may be removed from the last regeneration chamber and mixed in its hot condition with some fine particles of coal, and thus utilize the heat stored up in the inert material for the destructive distillation of the coal to give valuable products, including gas, and leave c oke or other carbonaceous material with the lime or other inert material. This mixture of inert material and carbon may then be transferred in its hot condition to one of the heatingchambers to therein store up some more vheatunits for use in a later regeneration chamber, and the process then becomes of a cyclic character. Impurities from the coal or coke will increase somewhat and may tend to produce a more easily fusing product at the high temperatures reached when storing up heat units. In order to avoid this,.some f the inert material may be removed so as to limit such upbuilding and additional ,amount of fresh inert material supplied, previously Heated to a' desirable temperature so as -to economize in heat. The discarded inert material, e. g. lime and some ash from coke, may be admixed with some of the materials separated from the reduced iron bythe magnetic treatment and the mixture burned, so Aas to produce cement. The heat units in the discarded material reduce the total amount required for the cement burning and is thus yadvantageous utilization of both discarded products. l

Some of the preheating of the iron ore may be carried out with some of the hot products -of combustion of the process. Heat units utilization is one object of the invention described.

It will thus be seen that the present invention provides for the reduction of iron oxides contained in certain types of iron or'es by reaction of carbon monoxide on the iron oxide, so that the reaction is of an exothermic character thus facilitating the reduction treatment g that the iron ore is preheated prior to the reduction step, utilizing heat units in the processethat the reduced iron products are cooled prior to mixing them with air; that the reduced iron is separated magnetically fromthe other materials; that such separated'materials may be used in the formation of cement; that carbon monoxide gas of high v The iron ore may be given apreheating treatment in a multiple hearth furnace, such as a Wedge furnace, then passed into a reduction furnace, which may be placed beneath the heating furnace, of a similar construction, and therein treated by the hot CO gases to reduce iron oxide into iron, and the material then passed into a lower furnace of similar design and therein cooled somewhat with non-oxidizing gases, and. later discharged into the atmosphere and subjectedV to a magnetic separation. Arrangements are provided to prevent interchange of gases between the three sections or three separate furnaces, except the gases used for cooling the product may be used for the preheating treatment, at

least in part, and then returned to the coolmg furnace. The more cooling done, the more heat units which can be transferred to the material in the preheating section or furnace. Additional heatinv may be provided in any suitable manner. inely divided iron ores may be thus treated.

I claim:

- The method ofv converting carbon dioxide into carbon monoxide', which comprises subjecting a mixture of inert material and carbon to a heating treatment to store mixture from gaseous'products -of combusup heat energy therein, purging the heatedV tion and bringing gases containing carbon dioxide into intimate contact with such heated mixture to convert carbon dioxide into a1-bon monoxide.

i2. ln the art of treating iron ores,'the steps which include preheating iron ore by a stream ot' hot gases containing carbon monoxide and a lesser amount of carbon dioxide, passing the cooled gases in substantially un.- changed chemical condition into intimate contact with a mixture ot reduced iron and gangue previously heated inthe reducing step, to cool the reduced iron and gangue, then passing the hot gases containing the carbon monoxide into intimate contact with preheated iron ore to eti'ect a reduction ot the iron oxide by the carbon monoxide, then passing the hot gases which contain an increased amount of carbon dioxide into contact with hot carbon to convert carbon dioxide into carbon monoxide and again passing the hot gases thus regenerated into intimate contactwith iron ore,substantially as described.

3. The improvement in claim 2, Which comprises subjecting the cooled solids to a magnetic separation treatment to separate reduced iron from gangue, mixing calcareous material with the gaugue and preparing a raw-mix, and burning the raw-mix to make cement clinker,burningsome ofthe combustib le gas after it has been used in the reduction step of the iron ore treatment, such gas containing carbon monoxide and carbon dioxide to generate heat for utilization in the burning step of the cement clinkerino.

4. The method of producing carbon monoxide, Which comprises subjecting a mixture comprising carbon and an inert material to combustion until the mixture is heated to a temperature adapted to decompose carbon dioxide, and passing a gas containing carbon dioxide, substantially free from nitrogen, into contact with the -heated mixture, whereby said carbon dioxide is converted into carbon monoxide. v

5. The method of converting carbon dioxide into carbon monoxide, which comprises subjecting a mixture comprising inert material and carbon` alternately to combustion to store up heat energy therein and to a treatment with material comprising carbon dioxide whereby carbon monoxide is produced and some of the stored heat energy is utilized; and utilizing the hot inert material, remaining after some of the carbon has been consumed, by mixing it with coal, whereby volatile constituents of the coal are driven oli'` and a `mixture comprising carbon and inert material is produced suitable for use in further carrying out of the process.

6. The method of reducing an oxide of a .metah-whicb comprises forming a reducingv gas While. at a high temperature treatment, passing the reducing gas While at a high ktemperature into counter-current contact witha metallic oxide to be reduced, whereby to heat the metallic oxide to a temperature sutlicient for initiating the reducing treatment and Isimultaneously to cool the resulting gas, passing such cooled gas counter-currently into contact with hot reduced metal-bearing material until such reduced material is cooled to a point where it can he safely advanced to other operations, and passing the reducing gas .thus heated into a reducing zone and counter-currently into contact with a metallic oxide which is being reduced. A

TI The process according to claim 6, in which the reducing gas contains carbon monoxide and resulting hot gases from the reducing zene are passed Without substantial loss of heat to a regenerator in which carbon dioxide is converted to carbon monoxide by contact with highly heated carbon, and hot car,-

bon monoxide, thus formed, is used in repeating the cycle.

8. The method of reducing iron ore which contains an oxide of iron, which comprises forming a reducing gas including carbon monoxide by a high temperature treatment; counter-currently passing the carbon monoxide, while still at a high temperature, into. contact with the metallic oxide to be reduced, whereby to heat the rawT material to a temperaturc sufficient for initiating the reducing reaction and simultaneously to coolthe gas; passing such cooled gas into Contact with h-ot .reduced metal until such metal is cooled 100 to a pointat which reoxidation thereof when brought into Contact with ordinary air will lbe substantially prevented; passing the mix- 'and passing the reducing gas thus heated into the reducing zone and into contactY with the iron-,oxide which is bein reduced.

9. The method of re nein iron oxide, which comprises preheating nely divided iron ore substantially to a temperature'at which reduction by carbon monoxidel will take place, preheating carbon monoxide to nea-r the temperature of the reducing reaction/by passing relatively cool reducing gas including carbon monoxide counter-current to hot finely divided solids including metallic iron derived from iron oxide by a reducing step of the process, introducing the heated gas into contact with the heated oxide and maintaining the temperature in the reaction zone by means of the exothermic reaction between carbon monoxide and the iron oxide.

10. The process for producin cement lfrom iron ore, which comprises orming af material containing calcareous, siliceous and aluminous constituents by mixing calcareous material with coke, utilizing the mixture in a carbon monoxide producer where the calcareous material serves as a heat retaining material and the coke as a source of carbon, intermittently burning the coke to store up heat therein and in the calcareous-material and between such burning steps passing gases including carbon dioxide into contact with the hotv mixture so as to convert carbon dioxide into. carbon monoxide, utilizing hot concentrated carbon monoxide thus formed for reducing an iron ore containing siliceous matter, coverting carbon di xide resulting from such reduction into carbon monoxide by treatment in a. carbon monoxide producer, reusing hot calcareous material in such a producer by mixing with additional coke and utilizing the resulting mixture of coke and calcareous material for reducing carbon di oxide to carbon monoxide, separating reduced iron from non-ferrous constituents, mixing the latter with the calcareous mixture ob-` tained from the producer and treating the resulting mixture to yproduce cement there- `from utilizing some of the heat energy available iro e m prior steps of the process.

11. The method of treating solids includ` ing an oxide of iron, which comprises the following steps:- -(a) passing such solids in finely divideds'tate countercurrent to Y hot gases under conditions adapted to bring the solids up to a temperature suilicient t0 eii'ect metallic iron; (c) passinghot gases froml chemical reduction of an oxi'de'of iron by means of carbon monoxide; (b) passing the preheated solids in finely divided state coulitercurrent to hot reducing gases containing carbon monoxide as the main reducing agent the gases up to a temperature at which carbon monoxide is capable of reducing FeO to Fe; (d) passing preheated ore from step (a) countei'current to hot reducing gases ofwhich carbon monoxide is the primary reducing agent, so as to reduce FeO to Fe and convert a portion only of the CO into CO2; and (e) removing hot gases, including CO and CO2 resulting from step (d), from treated iron ore and treating them by step (b) and burning fuel by means of air to supply heat to the carbon.

In testimony whereof l aix my signature.

LINN BRADLEY.

so as to eiect such a reduction and obtain step (b) ,-"these gases containing carbon monoxide and carbon dioxide, into intimate contact with hot solids including carbon so as to convert carbon dioxide thereof into carbon monoxide; (d) burning fuel and utilizing heat thereby generated to heat carbon utilized in step (c) (e) colin hot reducing gases produced by steps (c) f) passino' the cooled reducing gases including carbon monoxide countercurrent to the hot solids including iron from step (b) and utilizing the heated gases A from step (f) to reduce an oxide of iron in .sidual carbon monoxide; (b) passingshot gases containing carbon dioxide and carbon monoxide into intimate contact with hot carbon, so as to convert the carbon dioxide into iio l 

